Example Odour Control Report for a Brewery

Example Odour Control Report for a Brewery

Sample Brewery Company

Anytown, ON

1

Revision 1

May 2017

Introduction and Scope of Odour Control Reports

Purpose of the Example Odour Control Report

A person engaging in an activity prescribed for the purposes of the Environmental Activity and Sector Registry (EASR) by Ontario Regulation 1/17 (Air Emission EASR regulation) is required to have available at all times an Odour Control Report (OCR) if any of the circumstances set out in paragraph 5 of Section 24 of the regulation exists at the facility. If an OCR is required, the facility must prepare a facility-specific OCR that includes all the administrative and technical requirements set out in Section 27 of the Air Emissions EASR Regulation. In order to provide appropriate guidance materials and tools for facilities tasked with preparing an OCR, a total of six example OCRs have been developed by the Ministry of Environment and Climate Change (MOECC). One OCR is available for each activity with NAICS Codes listed in Table3 – Odour – Processes and Setback Distances of the EASR publication, and for each specific process listed in Table 4 – Odour – Processes and Setback Distances, as follows:

• Dog and Cat Food Manufacturing NAICS 311111 and Cooking or Drying Animal Products
• Sugar Manufacturing NAICS 311310
• Breweries NAICS 312120
• Spraying Operation (≥ 10 L/hr) and Printing (> 400 kg/hr ink usage)
• Wastewater Treatment – Lagoons, Uncovered Clarifiers, Sludge Management
• Food Frying

The Dog and Cat Food Manufacturing and Cooking or Drying Animal Products OCR was prepared such that it is applicable to NAICS 311111 listed in Table 3 and Cooking or Drying Animal Products, a Table 4 process. One combined OCR for Spraying Operations (Painting) and Printing was prepared. Where appropriate, the wastewater treatment OCR may be combined with the other OCRs.

The purpose of the example OCRs is to simplify the level of effort required by facilities when developing an OCR. These example OCRs contain useable information and are presented in a recommended OCR format.

Some sections in the example OCRs can be used as a draft for facilities, particularly with respect to the jurisdictional review and odour control options provided in Section 4. This information can be incorporated by facilities into their site-specific OCR. It is imperative, however, that the information be reviewed and validated as it reflects information available at the time this example OCR was prepared (January 2017). There may be advancements in control technologies or other changes to the sector or process that would need to be considered. It is the responsibility of the person preparing an OCR for a facility to ensure that the information, including the jurisdictional review and odour control options is complete.

As well, a number of sections of the OCR will require site-specific inputs and considerations, in particular, Section 2 where unique attributes at a specific facility should be detailed, Section 5 which presents the assessment of control option technical feasibility, and Section 6 which summarizes the status of current odour control measures at the facility.

These example OCRs include narrative guidance text boxes throughout for instructional purposes, as well as Appendices with further guidance materials and resources.

As the manufacturing processes may differ between facilities, this report should not be considered comprehensive for all facilities that require an OCR. A facility-specific OCR must be prepared to include all odorous sources at a facility and all different types of equipment as well as the materials being used. All reasonable effort must be made to identify odour reduction measures and procedures that are available from publicly accessible resources.

Table of Contents

Statements of Certification

Licensed Engineering Practitioner

Facility Representative

1Introduction

1.1Odour Control Report for a Brewery

1.2Sector Description

1.3Odour Control Report for Sample Brewery Co.

1.4Odour Control Report Content

2Facility Description

2.1Site Location and Location of Points of Odour Reception

2.2Facility Owner Legal Name and Contact Information

2.3Facility Operator Legal Name and Contact Information

2.4Production Rate and Operating Hours

2.5Facility Complaint History

2.6Unique Facility or Process Attributes

3Process Description

3.1General Process Description

3.2Identification of Odorous Contaminants

3.3Identification of Odour Sources and Source Groupings

4Sector Odour Control Measures

4.1Current Practices at Breweries

4.2Control Measures for Primary Sources at Sample Brewery Co.

4.3 Control Measures for Secondary Sources at Sample Brewery Co.

5Feasibility Assessment

6Adequacy of Current Odour Control Measures and BMPP

6.1Control Measures or Procedures to be Evaluated for Implementation

List of Tables

Table 1A – Odour Source Identification Table for Sample Brewery Co. (Primary Sources)

Table 1B – Odour Source Identification Table for Sample Brewery Co. (Secondary Sources)

Table 2 – Potential Alternative Odour Control Measures for Sample Brewery Co.

Table 3 – Potential Odour Control Measures for Sample Brewery Co. Primary Sources

Table 4 –Potential Odour Control Measures for Sample Brewery Co. Secondary Sources

Table 5 – Summary of Feasibility Assessment for Sample Brewery Co.

Table 6 – Control Measures or Procedures to beEvaluated for Implementation

Appendices

Appendix A – Supplemental Guidance for Developing a Facility Specific OCR

Appendix B – Control Equipment Descriptions

Appendix C – References

1

Statements of Certification

Licensed Engineering Practitioner

I confirm that based on the information provided to me, the information in the report is accurate as of the date it is signed and sealed.

Signature:

______

Name of Licensed Engineering Practitioner:

PEO License Number:

Date:

Facility Representative

I confirm that all information provided to the LicensedEngineering Practitioner in order to prepare this report was complete and accurate, and I have the authority to bind the company.

Signature:

______

Name of Facility Representative:

Position in the Company:

Date:

1.Introduction

1.1Odour Control Report for a Brewery

This Odour Control Report for the SampleBrewery Company(the ‘OCR’), a facility dedicated to beer production, was prepared to comply with the odour requirements of Ontario Regulation 1/17- Activities Requiring Assessment of Air Emissions (the ‘Air Emissions EASR Regulation’) for facilities that meet the following criteria:

• The facility is required to register their activities in the EASR under the Air Emissions EASR Regulation;
• The facility has completed an odour screening report in accordance with Section 25 of the Air Emissions EASR Regulation;
• The facility is a brewery with NAICS Code 312120, and has a design capacity greater than 20 million litres per year, which is an activity set out in Table 3 of Chapter 4 of the “Environmental Activity and Sector Registry – Limits and Other Requirements” (EASR Publication) published by the Ministry of Environment and Climate Change (MOECC), and available on a government website; and,
• The distance between the facility and the closest point of odour reception is less than the distance set out opposite the process in Table 3(Chapter 4 of the EASR publication explains what a point of odour reception is and how the distance between a point of odour reception and the facility must be measured).

A facility is required to prepare an OCR if any of the circumstances set out in paragraph 5 of Section 24 of the Air Emissions EASR Regulation exist at the facility. If an OCR is required, the facility must prepare a site-specific OCR that includes all the administrative and technical requirements set out in Section 27 of the Air Emissions EASR Regulation.

While this example OCR report pertains to industrial processes which engage in Beer Manufacturing, itcan also be used to assist facilities outside of this sector that have similar sources and emissions of odour in preparing their OCRs.

A facility is required to prepare a Best Management Practices Plan for Odour (BMPP) if any of the circumstances set out in paragraph 3 of Section 24 of the Air Emissions EASR Regulation exist at the facility at the time the most recent odour screening report is prepared. BMPPs must be prepared on a facility-basis. In this example, the Sample Brewery Company must, in addition to this OCR, develop and implement a BMPP. Best Management Practices (BMPs) are practices or procedures to prevent or minimize odorous effects. These may be general in nature and applicable to a wide range of facilities, or they may be facility-specific and intended to help reduce odorous releases from process operations or activities at an individual site. These practices are most easily implemented and most effective if they are incorporated into Standard Operating Procedures (SOPs) and training programs and workers are assigned responsibility and accountability. BMPs in general would not require additional engineering or significant process modifications or the installation of pollution control equipment.

Senior management at the facility must participate in the development of the OCR, and support the Licensed Engineering Practitioner by providing comprehensive and accurate information regarding site processes, activities, and emissions. The accuracy and completeness of the information provided for the preparation of the OCR must be certified by a representative of the facility.

1.2Sector Description

Brewing is one of Canada’s oldest industries. The beer industry is dominated by three major multinational companies; however, the vast majority of breweries produced less than 2,000 hectolitres (hL[1]) per year; many of these fall under the general classification of microbrewery at less than 1,800 hL per year.

There are approximately 60breweries across Canada that produce more than 15,000 hL annually. Twelve breweries in Canada report to the NPRI in 2015, of which two are located in Ontario.

It is not a mandatory requirement of the OCRs to include a sector description. However, it is recommended that a facility demonstrates that the activities and operations carried out at their site are consistent with other facilities in their sector (Section 1.4), and to highlight the differences or aspects of operations that are unique to their operation (Section 2.6).

1.3Odour Control Report for Sample Brewery Co.

An OCR is required for Sample Brewery Co., a large brewery with NAICSCode 312120 that producesmore than 20 ML/year;the NAICS code and production rate trigger the requirement for an OCR.The closest point of odour reception is less than 300metres from the nearest source of odour at the facility.

Chapter 4 of the EASR publication explains what a point of odour reception is and how the distance between a point of odour reception and the facility must be measured. The required setback distance for Breweries is 500metres as listed in Table 3 of the EASR Publication.

1.4Odour Control Report Content

This OCR for the Sample BreweryCo. has been prepared in accordance withthe Air Emissions EASR Regulation, and therefore includes the following required elements:

• Legal name of each facility owner and name under which the owner carries on business, if different from the legal name;
• If the facility operator is not an owner of the facility, the legal name of each facility operator and name under which each operator carries on business, if different from the legal name;
• Facility address;
• A facility description and a detailed process description;
• Measures and procedures used by facilities in this sector, or at facilities with similar sources of odour or activities, to prevent or minimize the discharge of odour, including control equipment, engineering controls, process optimization, pollution prevention, or other associated measures. In many cases, these measures were intended to abate specific contaminants but have the net effect of reducing odour emissions. For example, wet particulate matter control units such as scrubbers or rotoclones could serve to control odours;
• An analysis of the technical feasibility of implementing the measures and procedures identified, or potential combinations thereof at the facility;
• For the control measures identified as technically feasible but not implemented, rationale for why the control measures are notimplemented at the facility to prevent or minimize odour;
• A discussion of the adequacy of measures and procedures currently implemented and set out in the BMPP, to prevent or minimize odour effects from the facility;
• A statement by the Licensed Engineering Practitioner confirming that based on the information provided to the practitioner, the information in the report is accurate as of the date it is signed and sealed; and,
• A statement signed by the person engaging in the prescribed activity confirming that all information the person gave to the Licensed Engineering Practitioner in order to prepare the report was complete and accurate.

2.Facility Description

2.1Site Location and Location of Points of Odour Reception

The facility is located at 100 Sample Drive, in Anytown, Ontario.

The UTM co-ordinates for the facility are:

• Zone – 17
• UTM Easting - 723000 m
• UTM Northing - 4840000 m

Sample Brewery Co. is located in an industrial area that lies adjacent to a residential development. The closest point of odour reception is a residence located 200 metres from the fenceline of the facility and 300 metres from the nearest odour source at the facility, which is less than the required setback distance of 500 metres from Table 3 of the EASR Publication. There are other residences, as well as a public sports field, within 500 metres of the facility.

2.2Facility Owner Legal Name and Contact Information

Legal name of the owner: Mr. Ben Malterson

Contact Information: 519-123-4567;

2.3Facility Operator Legal Name and Contact Information

The facility is operated by the owner.

The Air Emissions EASR Regulation requires that the OCR sets out the legal name of each owner of the facility, and the name under which each owner carries on business, if it is not the owner’s legal name. Further, if the person who operates the facility is not an owner, the report must set out the legal name of each person who operates the facility and the name under which each operator carries on business, if it is not the operator’s legal name.

2.4Production Rate and Operating Hours

The facility produces up to 30 ML of beer annually.

The operating hours are typically 24 hours per day, 7 days per week. There is one week of scheduled shutdown per year.

2.5Facility Complaint History

The facility maintains accurate records of all complaints received and the measures taken to investigate and respond to each complaint following the process outlined in the facility BMPP. This includes complaints made to the facility directly, as well as those made to the local MOECC office. There have been no complaints received over the last 5 years.

It may be beneficial for a facility to document all complaints received and their resolution in the OCR. Some complaints may have been resolved or were the result of a process upset. Resolved complaints could lead to changes or improvements in the facility’s BMPP for odour. However, documenting complaints in an OCR is not a legal requirement.

2.6Unique Facility or Process Attributes

Each brewery is unique, and there are process attributes that are unique to a given facility.Brewery emissions are also affected by the brewing recipes.

At the Sample Brewery Co., the following processes, activities, or sources may be considered unique when compared to a typical large brewery:

• In-house malting is conducted;
• Ethanol recovery from waste beer is achieved via distillation as a saleable by-product; and,
• There are no outdoor stockpiles of raw materials or wastes.

Each brewery is unique and source to source variations in process, source configurations or location at the facility can significantly affect emissions and off-property impacts. The emission variations result from differences in the raw materials, the type and age of equipment used, total production, etc. All of these factors and production details need to be clearly described in the OCR.

3.Process Description

3.1General Process Description

At the Sample Brewery Co., beer production involves the following main process stages:

• Bulk materialshandlingandstorage;
• Malting;
• Brewhouse operations;
• Fermentation and aging;
• Filling room operations;
• Ethanol recovery by distillation;
• CO2 purification; and,
• Auxiliary services.

3.1.1Bulk Materials Handling and Storage

The bulk handling of materials includes the following:

• Storage silosfor dry malt and grains, dry brewers grain, dry waste yeast feed, and other aggregates (diatomaceous earth, lime);
• Large liquid holding and storage tanks for ingredients, process intermediates, or product; and,
• Sumps and trenching to collect spillage in the brewhouse, fermentation, or filling rooms.

3.1.2Malting

Smaller breweries typically purchase malted grain (malt) from malting operations, and store dry malt in silos. Larger breweries, such as the Sample Brewery Co., conduct in-house malting.The malting process starts with steeping grain in water to soften, germination in tanks, and roasting in a kiln to halt germination and dry the malt. The malt is ground and stored in hoppers or silos.

3.1.3Brewhouse Operations

The milled malt is fed to the mash tun with hot waterfor mashing, which converts grain starches toa slurry of fermentable sugarscalled mash.The Sample Brewery Co. uses a mash infusion technique, while other breweries may use an alternate process such as decoction or double mashing. All three processes require elevated temperatures. The mash is strained in a lautertun, which separates insoluble grain residues from the mash. Strainmasters are used in some large breweries in place of lautertuns. The product of the lautertun is called wort. The recovered brewer’s grain is a saleable animal feed by-product.

A brew kettle is used to boil the wort for 90 to 120 minutes, during which time hops are added. This boiling is followed by straining out of the hops andthen settling out of the remaining insoluble material called trub.Trub is recovered and combined with the brewer’s grains for drying as a saleable by-product.After settling, hot wort is pumped to either a single or a two-stage cooling system, followed by yeast addition as cooled wort is pumped to the fermenters.

3.1.4Fermentation, Aging, and Secondary Fermentation

Fermentation takes place in large tanks with capacities over 1,000 barrels (117,000 L) for medium to large breweries (such as Sample Brewery Co.). The tanks are closed to the atmosphere; however, some breweries may operate with open tanks. Fermentation is a biological process in which yeast converts sugars into ethyl alcohol (ethanol), carbon dioxide (CO2), and water. The type of yeast used and the length of the fermentation process vary among breweries and types of beer. After primary fermentation, waste yeast is typically removed from the liquid by centrifuges, or other means. The liquid is pumped to low-temperature aging tanks, and a small quantity of freshly fermenting wort may be added. Viable yeast may be recovered for reuse in the fermentation process; waste yeast may bedistilled to recover residual alcohol, sold to animal feed processors, or disposed of with process wastewater. After the beer is aged, centrifugation and/or filtration with diatomaceous earth filtersare used to remove solids and the product is pumped to beer storage tanks and to the filling lines.